Whelen 810CA0ZR User Manual

®

ENGINEERING COMPANY INC.

51 Winthrop Road
Chester, Connecticut 06412-0684
Phone: [phone]

Installation Guide:

810 Series Lighthead

(Scenelight)

Fax: [phone]
Internet: www.whelen.com
Sales e-mail: [e-mail]
Canadian Sales e-mail: [e-mail]
Customer Service e-mail: [e-mail]

Safety First

This document provides all the necessary information to allow your Whelen product to be properly and safely installed.
Before beginning the installation and/or operation of your new product, the installation technician and operator must
read this manual completely. Important information is contained herein that could prevent serious injury or damage.

• Proper installation of this product requires the installer to have a good understanding of automotive electronics,
systems and procedures.

• If mounting this product requires drilling holes, the installer MUST be sure that no vehicle components or other
vital parts could be damaged by the drilling process. Check both sides of the mounting surface before drilling
begins. Also de-burr any holes and remove any metal shards or remnants. Install grommets into all wire
passage holes.

• If this manual states that this product may be mounted with suction cups, magnets, tape or Velcro®, clean the
mounting surface with a 50/50 mix of isopropyl alcohol and water and dry thoroughly.

• Do not install this product or route any wires in the deployment area of your air bag. Equipment mounted or
located in the air bag deployment area will damage or reduce the effectiveness of the air bag, or become a
projectile that could cause serious personal injury or death. Refer to your vehicle owner’s manual for the air bag
deployment area. The User/Installer assumes full responsibility to determine proper mounting location, based
on providing ultimate safety to all passengers inside the vehicle.

• For this product to operate at optimum efficiency, a good electrical connection to chassis ground must be
made. The recommended procedure requires the product ground wire to be connected directly to the NEGATIVE
(-) battery post.

• If this product uses a remote device to activate or control this product, make sure that this control is located in
an area that allows both the vehicle and the control to be operated safely in any driving condition.

• Do not attempt to activate or control this device in a hazardous driving situation.

• This product contains either strobe light(s), halogen light(s), high-intensity LEDs or a combination of these
lights. Do not stare directly into these lights. Momentary blindness and/or eye damage could result.

• Use only soap and water to clean the outer lens. Use of other chemicals could result in premature lens cracking
(crazing) and discoloration. Lenses in this condition have significantly reduced effectiveness and should be
replaced immediately. Inspect and operate this product regularly to confirm its proper operation and mounting
condition. Do not use a pressure washer to clean this product.

• It is recommended that these instructions be stored in a safe place and referred to when performing
maintenance and/or reinstallation of this product.

• FAILURE TO FOLLOW THESE SAFETY PRECAUTIONS AND INSTRUCTIONS COULD RESULT IN DAMAGE TO
THE PRODUCT OR VEHICLE AND/OR SERIOUS INJURY TO YOU AND YOUR PASSENGERS!

Automotive: Lightheads

For warranty information regarding this product, visit www.whelen.com/warranty

©2004 Whelen Engineering Company Inc.
Form No.13890D (090310)

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Installation:

1. Position the 810 lighthead in its mounting location. Make sure
that the 810 will not interfere with any existing equipment.
Also be aware of any and all items on the opposite side of the
mounting surface to prevent any possible damage to existing
components.

2. Position the supplied mounting template on the mounting
location and temporarily secure it to the surface. Be sure the
template is FLAT against the surface.

NOTE: Before proceeding, place the reflector against the
template and confirm that the mounting holes on the
template line up with the actual mounting holes on the
reflector.

NOTE: Be sure the drainage provisions for both the reflector
and gasket are on the bottom. Each gasket is labeled.

3. Using a .250” drill bit, drill the mounting holes as shown on
the template.

4. The rectangle on the template represents the recommended
location for the wiring hole. Drill a 1” wire access hole
centered as shown on the template. Deburr and install an
appropriately sized grommet in this hole (customer supplied).

5. Butt splice the 2 RED wires together as shown. Repeat for
the 2 WHITE wires. Connect the RED wire to +12VDC and
the WHITE wire to chassis ground. Fuse the RED wire @ 5
amps.

WARNING! All customer supplied wires that connect to the
positive (+) terminal of the battery, must be sized to supply at
least 125% of the maximum operating current, and fused “at
the battery” to carry that load.

6. Test operation of the 810 before securing it to the vehicle.

7. Install the round hole grommets into the mounting holes.
Position the lens onto the reflector. Place this assembly onto
the mounting surface and secure using the supplied
mounting screws.

WARNING! To insure proper mounting of this product,
special round hole screw grommets have been included with
your mounting hardware. Do not install this product without
these grommets! Over-tightening the mounting screws may
cause permanent damage to the reflector and/or lens!

Specifications

INPUT VOLTAGE - 13.5 VDC + 20%
INPUT CURRENT @ 12.8 VDC - 3.9 AMPS

IMPORTANT: Do not install
bulbs exceeding 27 watts.

Mounting Screw

(#8 x 1 1/2“ P.P.H.S.M.S.)

IMPORTANT:The outer surfaces of this
product may be cleaned with mild soap
and water. Use of any other chemicals
may void product warranty.
Do not use a pressure washer.

Reflector

P/N 68-5982436-02

(Scenelight / Optic / Clear)

Lens

P/N 68-1984058-30

RED

(+12VDC)

Mounting Gasket

P/N 38-0483047-00

WHITE

(GROUND)

Round Hole

Screw Grommet

P/N 21-1708080603

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